Plug wires

[SD_GS500E]

So the bike started vibrating like crazy lately, and from the posts I read, it seemed that synching the carbs was the right approach.  Well I tend to read way too much before I start a project, so all day I've been reading about carb synching, my Pro Motion synch tool arrived today.  But one of the things I read was, "Make sure your valves are adjusted or you're just wasting your time."

So I got the valve shim tool and a magnet as well, so off I go to start checking valve shims.  first one, my .08mm won't fit, but my .04mm does. Right side intake good!  the other three won't fit the .04 mm, so I figure they likely need to be adjusted.

However, when I pulled the cover out, I realized there was a wire just laying there...turns out it was the spark plug wire.  Is there a way to stick, that thing back in the coil?  Or am I out $100 and the time it takes to ship a new one?

It also seems there are no numbers on the shims.  Is a set of cheap calipers enough to get measurement from one of these shims or do I need some hi-tech micrometer?  I figure since it's worn, it will likely have shrank anyway from the original reading.

Thanks heaps!

[Janx101]

err... had one of mine pulled out by a idiot in a hurry ... (me ...    ) ... checked around on here... a little dab of dialectric grease (available from auto shop) on the exposed wire... 'screw' the cable back into the spot... not heaps hard but firmly! .. 

it may come loose again sooner or later .. and isnt as fixed in there as from new... but its easy enough to fix... i believe gsJack has been doing this trick since Moses played linebacker for Jerusalem! 

[The Buddha]

You can screw it onto the plug cap.
The coil side isn't unscrewable. If that broke, you have to get a new coil.
Cool.
Buddha.

[Janx101]

You can screw it onto the plug cap.
The coil side isn't unscrewable. If that broke, you have to get a new coil.
Cool.
Buddha.

disagree .. but  ... i followed Jack and others instructions... works good!... yep definitely coil end!

[gsJack]

Before Moses!  I've had a loose one for years.  Best to cut about 1/4" off the end of the wire, add the big dab of diaelectric grease, and screw it in as tight as you can.  They come from factory screwed in and bonded in place and you can't turn a good one.  I just redid it once a year when I was doing valves and had no more trouble with it.  Got a 6' length of plug wire and replaced that one when it got shorter from several cuts.  Best fix would be a new coil and wire properly bonded together.

That was on my 02 GS and after I had that loose one on the 02 I walked over to the old 97 in the garage and easily pulled both wires from the coils.  Just got by with that one for 80k miles.